Conditioning module for conditioning two fluids that are substantially at rest

ABSTRACT

A fluid conditioning module, comprising: a pump and at least one additional conditioning device, wherein the pump generates a fluid cycle of at least one fluid to be conditioned between a fluid sump, the pump and the conditioning device, and wherein the at least one fluid is substantially at rest in the fluid sump.

The present invention relates to a conditioning module for conditioning fluids that are substantially at rest in a fluid sump, in particular differential oil or battery fluid in a motor vehicle. The invention relates further to a motor vehicle equipped with such a conditioning module or to a gearbox of an alternative energy source equipped with such a conditioning module.

From the prior art, cooling modules and filter modules are known. They filter or cool in most cases pressurized fluids such as, for example, lubricating oil of an internal combustion engine. Often, these modules come with the required pumps already integrated which move all of the lubricating oil present in the circuit. Since the respective fluids have to be moved over relatively long distances, the pumps are designed correspondingly large and powerful.

From EP 838 577 B1, for example, such a conditioning module with filter, cooler and integrated pump is known which drives the entire oil circuit for supplying oil to the internal combustion engine. Due to the relative high pressures within the oil circuit, said conditioning module must be of robust construction and cannot be minimized much.

It is the object of the present invention to propose a conditioning module by means of which the performance of previously non-conditioned aggregates can be increased.

This problem is solved according to the invention by the subject matters of the independent claims. Advantageous embodiments are subject matter of the dependent claims.

The invention is based on the general idea to provide a conditioning module for fluids which are substantially at rest and are currently not conditioned such as, for example, differential oil in a differential, and to thereby increase the performance of the aggregates which are now operated for the first time with the conditioned fluids. For this purpose, the conditioning module has a pump and at least one further conditioning device, in particular a cooling device, wherein the pump generates a fluid cycle of the fluid to be conditioned between a fluid sump of the aggregate, the pump and the conditioning device. Hereby it is possible for the first time to condition previously non-conditioned fluids such as, for example, differential oil or battery fluid and to thereby increase the performance capability of such aggregates.

Further important features and advantages arise from the sub-claims, from the drawings, and from the associated description of the figures based on the drawings.

It is to be understood that the above mentioned features and the features yet to be explained hereinafter can be used not only in the respectively mentioned combination but also in other combinations or alone without departing from the context of the present invention.

Preferred exemplary embodiments of the invention are illustrated in the drawings and are explained in the following description in more detail, wherein identical reference numbers refer to identical, or similar, or functionally identical components.

In the figures, schematically:

FIG. 1 shows an overview over possibilities of use in a hybrid vehicle,

FIG. 2 shows a conditioning module according to the invention on a gearbox,

FIG. 3 shows a conditioning module according to FIG. 2 but with open gearbox housing,

FIG. 4 shows a possible structure of the conditioning module

FIG. 5 shows an illustration as in FIG. 4, but from a different perspective,

FIG. 6 shows an interior view of the conditioning module,

FIG. 7 shows an exploded illustration of the conditioning module,

FIG. 8 shows a bottom view of the conditioning module.

FIG. 1 shows a possible use of the conditioning module 1 according to the invention. Up to now, usually, the engine oil, the fuel or sometimes also the gearbox oils are conditioned. With the conditioning module 1 according to the invention it is now possible, for example in a vehicle with hybrid drive, to also condition a fluid of a battery 12 as well as different gearbox fluids such as the one of a differential 10 on a front axle and on a rear axle. This involves fluids which are substantially at rest and which have previously not been conditioned. However, by conditioning, the performance of said aggregates can be increased. In general, the conditioning module 1 can be used for any fluids which are at rest, in particular in the area of drives or gearboxes of alternative energy sources. Merely as an example of this, wind power plants, wave power plants, tidal power plants or solar plants are to be mentioned.

Ideally, the conditioning module 1 is self-sufficient so that no cable connections or coolant connections are required. If air-cooled heat exchanger devices 2 are used for conditioning the fluid, no coolant connections are necessary. From the temperature difference that can exist in the heat exchanger device 2, under certain circumstances, a pump 3 associated with the conditioning module 1 can be operated so that separate electrical connections are not required. In the event that the recovered waste heat is intended to be used for other areas of the vehicle, electrical connections for the pump 3 and coolant connections for the heat exchanger device 2 are needed. Preferably, very small types of pumps 3 with low power consumption are used for this purpose. If, for example, micro annular gear pumps are used, no pulsations occur and the liquid is uniformly conditioned which is due to the fact that the flow generated by this type of pumps 3 is very uniform. In order that a pump 3 can be used which generates only low pressures, it is also required that the heat exchanger device 2 generates a pressure loss as low as possible.

FIG. 2 shows a conditioning module 1 mounted to a differential/differential gear 10. The conditioning module 1 is still relatively large relative to the gearbox 10, wherein the rule applies: the smaller the more versatile. In order to be able to fasten, in particular screw, the conditioning module 1 onto the gearbox 10, for example, receptacles 110 are provided. However, it is also conceivable to fasten it with other means.

In FIG. 3, a gearbox housing 100 of the gearbox 10 is illustrated in the open state. Due to gravity, a fluid sump, in particular oil sump, accumulates in the lower part of the gearbox housing 100. In modern gearboxes, this can result in temperature problems. Here, the conditioning module 1 according to the invention is targeted on keeping the temperature of the fluid, in particular of the gearbox oil, low. Through an inlet opening 71 in the gearbox housing 100 and when the pump 3 is switched on, the gearbox oil which, in this case, is the pressureless fluid to be conditioned, can be pumped into the conditioning module 1. The inlet opening 71 is preferably arranged in the gearbox housing 100 in such a manner that the gearbox oil can be pumped from a sump without problems. After flowing through the conditioning module 1, the gearbox oil is fed again to the gearbox 10 via the outlet 4 and the outlet opening 41. Between the inlet opening 71 and the outlet opening 41 there should be a spatial distance d to ensure that no fluid is sucked in again which has just been conditioned. Ideally, there is also a height difference h between the inlet opening 71 and the outlet opening 41 so that it is ensured that in fact the gearbox oil sump is conditioned. In different cases of use it can make sense to select a different distance d and a different height h.

The pump 3 can be configured such that it generates a slow but uniform fluid flow in the gearbox housing 100. However, the pump can also be configured such that depending on the demand, a different pump volume per second is supplied through the conditioning module 1. This is controlled by a control circuit integrated in the conditioning module, wherein the control circuit can be placed in an extremely small SMD chip. The volume of the fluid to be conditioned depends also on the configuration of the heat exchanger device 2. Suitable as heat exchanger devices 2 are all compact and efficient heat exchangers which require a small installation space.

In FIG. 4, the structure of the conditioning module 1 is illustrated. It consists of the following components. The following components are illustrated here: the heat exchanger device 2, the pump 3, a module base plate which consists here of two pieces, namely a module bed plate 5 and a module cover plate 9 which closes the channels of the media in the module bed plate 5, an outlet 4 and an inlet 7. Further components, which are not shown here, can also be provided, e.g., a filter element which can also be replaceable, a thermostatic valve, a switch of any kind for switching on and off the conditioning module 1, if necessary, a water separator, etc.

The components and the conditioning module 1 itself are fastened by means of through-openings 6, which can be configured in particular as bore holes, to a gearbox housing 100 or also to other containers which contain the fluid to be conditioned. For the pump 3, an opening 73 is provided in the module bed plate 5 in which opening the moving elements of the pump 3 are inserted. The pump 3 then pumps the fluid to be conditioned through the opening 72 which corresponds with opening 71 in the gearbox housing 100 in which the fluid to be pumped is present. If, as in the exemplary embodiment shown here, a cooling fluid-cooled or water-cooled module bed plate 5 is used, then, for example, the inlet ports 57 and outlet ports 58 for the cooling fluid are arranged on the module bed plate 5. Said ports can also be attached at a different position on the heat exchanger device 2. For this reason, they are illustrated only schematically in this figure.

FIG. 5 shows the installable conditioning module 1 as a whole. Due to the pump 3 engaging in the module bed plate 5 of the conditioning module 1, the size of an opening 72 of the module bed plate 5 is reduced. In the module bed plate 5, a receptacle is provided for a seal 56 which seals the transition of the inlet 7 to the gearbox housing 100 where the fluid to be conditioned is present. Likewise, a seal 55 is provided at the outlet 4, which seal is also received in a suitable receptacle on the module bed plate 5. The conditioning module 1 is fastened by screws 60 or other fasteners in a form-fitting and tight manner to the gearbox housing 100 in which the fluid to be conditioned is present. The outlet 4 preferably has a length that allows that the fluid to be conditioned at the other end of the gearbox housing 100, in which the fluid to be conditioned is present, flows back into the gearbox housing 100. The distance d between the inlet opening 71 and the outlet opening 41 should be the maximum distance. Also, a height difference h between the inlet opening 71 and the outlet opening 41 optimizes the conditioning of the fluid.

FIG. 6 shows the open module bed plate 5 without module cover plate 9. The inserted pump 3 with its gear wheels 33 is visible. The fluid to be conditioned is supplied to the heat exchanger device 2 via a channel 80 which is arranged in the module bed plate 5. The channel walls 52 of the channels 80 and 81 support the module bed plate 5. The arrow drawn as broken line represents the flow of the liquid through the heat exchanger device 2. From the heat exchanger device 2, the fluid to be conditioned gets back again via the channel 81, the outlet opening 42, the outlet 4 and the outlet opening 41 into the gearbox housing 100 from which it was pumped.

In the exemplary embodiment shown here, the module base plate is located between the gearbox housing 100 in which the fluid to be conditioned is present and the further components such as pump 3 and heat exchanger device 2. However, the module base plate can also be configured such that the further components are arranged in the module base plate. This is advantageous if the module base plate is made of plastic. It can also be made of metal, preferably aluminum, as in the shown exemplary embodiment, and can be manufactured and soldered together with the heat exchanger device 2 in a single process.

The module base plate shown here can be made in two pieces or more pieces, as needed.

FIG. 7 shows an exploded illustration of the conditioning module 1. All required components are illustrated. Corresponding to the channels 80 and 81 in the module bed plate 5, the openings 94 and 95 are arranged in the module cover plate 9 for the inflow and outflow of the fluid to be conditioned from the heat exchanger device 2. The openings and 91 are available for the coolant if the heat exchanger device 2 is connected via the module bed plate 5 and associated connection ports 57 and 58 to a cooling circuit. The outer wall 50 and the channel walls 52 of the module bed plate can be relatively thin because the fluid to be conditioned is almost pressureless. The screws 60 fasten the conditioning module 1 to the gearbox housing 100 by means of the through-openings 6.

The shown conditioning module 1 for pressureless fluids in a vehicle is suitably structured for the use with a gearbox 10. However, if a sump generation with the fluid at rest does not take place, the conditioning module 1 has to be configured differently with respect to its structure. The arrangement of pump 3 and heat exchanger device 2 is merely exemplary. Also, the structure of the module base plate has to be adapted according to the requirements because it contains the feeding and discharging channels of the media. Depending on the use of the conditioning module 1 it can also be required to protect the entire conditioning module by a cap against environmental influences.

FIG. 8 is the bottom view of the conditioning module 1. The tubular outlet 4 is not drawn in here. The seals 55 and 56 seal the module bed plate 5 against the gearbox housing 100. 

1. A fluid conditioning module comprising: a pump and at least one additional conditioning device, wherein the pump generates a fluid cycle of at least one fluid to be conditioned between a fluid sump, the pump and the conditioning device, and wherein the at least one fluid is substantially at rest in the fluid sump.
 2. The fluid conditioning module according to claim 1, wherein the additional conditioning device is at least one of a filter device, a drying device and a heat exchanger device.
 3. The fluid conditioning module according to claim 1, wherein the conditioning module has at least one inlet and one outlet, which both are directly connected to the fluid sump.
 4. The fluid conditioning module according to claim 3, wherein at least one seal is provided in at least one of the inlet and the outlet.
 5. The fluid conditioning module according to claim 1, wherein the pump is a micro annular gear pump for a low operating pressure.
 6. The fluid conditioning module according to claim 1, wherein the pump is a miniature gear pump.
 7. The fluid conditioning module according to claim 2, wherein the heat exchanger device is a self-sufficient air-cooled fluid heat exchanger with plates and air fins.
 8. The fluid conditioning module according to claim 2, wherein the heat exchanger device is a fluid-cooled heat exchanger with plates.
 9. The fluid conditioning module according to claim 2, wherein the heat exchanger device is a self-sufficient air-cooled heat exchanger with at least one of flat tubes, air fins and collector tubes.
 10. The fluid conditioning module according to claim 1, wherein an aperture of the inlet to the conditioning module is arranged at a spatially large distance to an aperture of the outlet in the fluid sump.
 11. A motor vehicle, comprising: at least one conditioning module having at least one conditioning device; at least one pump; and a fluid sump, wherein the pump generates a fluid cycle of at least one fluid to be conditioned between the fluid sump, the pump and the conditioning device, and wherein the at least one fluid is substantially at rest in the fluid sump.
 12. (canceled)
 13. The fluid conditioning module according to claim 1, wherein the at least one fluid is at least one of a differential oil and a battery fluid.
 14. The motor vehicle according to claim 11, wherein the additional conditioning device is at least one of a filter device, a drying device and a heat exchanger device.
 15. The motor vehicle according to claim 11, wherein the conditioning module has at least one inlet and one outlet, which both are directly connected to the fluid sump.
 16. The motor vehicle according to claim 15, wherein at least one seal is provided in at least one of the inlet and the outlet.
 17. The motor vehicle according to claim 11, wherein the pump is at least one of a miniature gear pump and a micro annular gear pump for a low operating pressure.
 18. The motor vehicle according to claim 14, wherein the heat exchanger device is a self-sufficient air-cooled fluid heat exchanger with plates and air fins.
 19. The motor vehicle according to claim 14, wherein the heat exchanger device is a fluid-cooled heat exchanger with plates.
 20. The motor vehicle according to claim 14 wherein the heat exchanger device is a self-sufficient air-cooled heat exchanger with at least one of flat tubes, air fins and collector tubes.
 21. The motor vehicle according to claim 11, wherein an aperture of the inlet to the conditioning module is arranged at a spatially large distance to an aperture of the outlet in the fluid sump. 